Aprilia SR50

UPDATES
SR 50 TE
UPDATES
1
SR 50 TE (Engine C361M)
1.1
1.7
1-1
UPDATES
SR 50 TE
CONTENTS
1.1.
GENERAL INFORMATION ..........................................................................................................3
1.1.1.
REFERENCE MANUALS.....................................................................................................3
1.1.2.
VEHICLE IDENTIFICATION ................................................................................................4
1.2.
SPECIFICATIONS .......................................................................................................................5
1.2.1.
SPECIFICATIONS...............................................................................................................5
1.2.2.
LUBRICANTS TABLE .........................................................................................................7
1.3.
REGULAR MAINTENANCE .........................................................................................................8
1.3.1.
REGULAR MAINTENANCE SHEET ....................................................................................8
1.3.2.
FIXING ELEMENTS.............................................................................................................9
1.3.3.
MIXER OIL PUMP ADJUSTMENT .....................................................................................11
1.3.4.
IDLE ADJUSTMENT..........................................................................................................12
1.4.
FUEL SUPPLY SYSTEM ...........................................................................................................13
1.4.1.
PUMPING OUT THE FUEL TANK .....................................................................................13
1.4.2.
REMOVING THE FUEL TANK...........................................................................................14
1.4.3.
REMOVING THE EXHAUST SYSTEM ..............................................................................15
1.4.4.
REMOVING THE ENGINE.................................................................................................16
1.4.5.
INSTALLING THE ENGINE ...............................................................................................21
1.5.
CHASSIS...................................................................................................................................26
1.5.1.
REMOVING THE REAR MUDGUARD...............................................................................26
1.5.2.
REMOVING THE CRANKCASE COVER ...........................................................................27
1.5.3.
REMOVING THE CENTRAL STAND .................................................................................28
1.5.4.
REAR WHEEL DIAGRAM..................................................................................................29
1.5.5.
REMOVING THE REAR WHEEL .......................................................................................30
1.5.6.
REMOVING THE REAR WHEEL HUB...............................................................................31
1.5.7.
REMOVING THE REAR BRAKE DISC ..............................................................................32
1.5.8.
REMOVING THE SHOCK ABSORBER .............................................................................33
1.5.9.
REMOVING CONNECTION ELEMENTS...........................................................................34
1.6.
ELECTRICAL SYSTEM .............................................................................................................35
1.6.1.
COMPONENTS INSPECTION...........................................................................................35
1.6.2.
ELECTRICAL DIAGRAM ...................................................................................................39
1.7.
GENERAL INFORMATION ........................................................................................................41
1.7.1.
REFERENCE MANUALS...................................................................................................41
1.8.
SPECIFICATIONS .....................................................................................................................42
1.8.1.
SPECIFICATIONS.............................................................................................................42
1.9.
REGULAR MAINTENANCE .......................................................................................................44
1.9.1.
REGULAR MAINTENANCE SHEET ..................................................................................44
1.10.
SUPPLY SYSTEM .................................................................................................................45
1.10.1.
REMOVING THE SPARK PLUG........................................................................................45
1.10.2.
REMOVING THE CARBURETTOR....................................................................................46
1.10.3.
REMOVING THE VACUUM FUEL TAP .............................................................................49
1.10.4.
REMOVING THE ENGINE.................................................................................................52
1.11.
ELECTRICAL SYSTEM .........................................................................................................56
1.11.1.
COMPONENTS INSPECTION...........................................................................................56
1.11.2.
ELECTRICAL DIAGRAM ...................................................................................................59
1-2
1.1.
1.1.1.
UPDATES
GENERAL INFORMATION
REFERENCE MANUALS
ENGINE WORKSHOP MANUALS

aprilia part# (description)
8140731
8140732
8140733
8140734
8140735
8140736
SPARE PARTS CATALOGUES
553Y
SPECIAL TOOLS MANUALS
001H
USE AND MAINTENANCE BOOKLETS
8202336
8202381
8202382
CHASSIS WORKSHOP MANUALS
8140123
8140124
1-3
UPDATES
1.1.2.
VEHICLE IDENTIFICATION
POSITION OF THE SERIAL NUMBERS

These numbers are required for the vehicle registration.
IMPORTANT Altering the identification numbers can incur
serious penal and administrative penalties. Altering the
chassis number in particular, will immediately annul the warranty.
Chassis number
The chassis number is stamped on the steering stem.
Engine number
The engine number is stamped on the rear side, near the
shock absorber.
1-4
UPDATES
1.2.
1.2.1.
SPECIFICATIONS
SPECIFICATIONS
DIMENSIONS
Max. length
Max. width
Max. height (to the windshield)
Height to the saddle
Wheelbase
Minimum clear height from the ground
Running conditions weight
ENGINE
Type
Model
Number of cylinders
Total capacity
Bore/stroke
Compression ratio
Starter
Engine idle rpm
Clutch
Gear
Cooling
CAPACITY
Fuel (reserve included)
Fuel reserve
Transmission oil
Mixer oil (reserve included)
Mixer oil reserve
Coolant
Seats
Max vehicle load (pilot+luggage)
Max vehicle load (pilot+ passenger + luggage)
TRANSMISSION
Variator
Primary
Ratios
- minimum for continuous variable transmission
- maximum for continuous variable transmission
Secondary
ELECTRONIC INJECTION SUPPLY
MODEL
- Type
Diffuser
ELECTRONIC INJECTION SUPPLY
Fuel
CHASSIS
Type
SHOCK ABSORBERS
Front
Travel
Rear
Travel
BRAKES
Front
Rear
WHEELS
Type
Front
Rear
1775 mm
720 mm
1200 mm
820 mm
1265 mm
160 mm
106 kg
Two-stroke
C361M
Horizontal single cylinder
49.38 cm
40 mm / 39.3 mm
12.4 0.5 : 1
Electric
2000 50 rpm
Dry automatic centrifugal
Automatic continuous variator
Liquid
8 litres
2 litres
130 cm
1.6 litres
0.5 litres
1.2 litres (50% antifreeze with ethylene glycol + 50% water)
1
(2 in countries which allow passengers to be carried)
105 kg
180 Kg
(in countries which allow passengers to be carried)
Automatic continuous
V-belt
3.07
0.78
gears
ELECTRONIC INJECTION
20 mm
Premium unleaded petrol DIN 51607,
with minimum octane number 95 (N.O.R.M.) and 85
(N.0.M.M.)
Split single beam
Telescopic fork
90 mm
Hydraulic single shock
72 mm
Disc 190 mm with hydraulic transmission
Alloy
3.50 x 13"
3.50 x 13"
1-5
UPDATES
Type
Front
Rear
STANDARD INFLATION PRESSURE
Front
Rear
INFLATION PRESSURE WITH PASSENGER
Front
Rear
IGNITION UNIT
Type
Ignition advance
SPARK PLUG
Standard
Spark plug electrodes distance
ELECTRICAL SYSTEM
Battery
Fuses
Alternator (permanent magnet)
BULBS
Low-beam
Low-beam / High-beam
Turn indicators
Rear side light
Rear stop light
Dashboard lighting
INDICATOR LIGHTS
Low-beam
High-beam
Turn indicators
Mixer oil reserve
Fuel reserve
Injection Check
1-6
tubeless
130/60 13" 53J
130/60 13" 53J
180 kPa (1.8 bar)
200 kPa (2.0 bar)
180 kPa (1.8 bar)
220 kPa (2.2 bar)
T.C.I.
variable 20 at 3000 rpm 17 at 7500 rpm
CHAMPION RG6 YC
0.9 mm
Maintenance free 12 V - 5 Ah
10 A 15 A
12 V 165 W
12 V 15 W
12 V 35/35 W
12 V 10 W
12 V 5 W
12 V 10 W
12 V 1.2 W
12 V 1.2 W
12 V 1.2 W
12 V 2 W
12 V 2 W
12 V 1.2 W
12 V 2 W
UPDATES
1.2.2.
LUBRICANTS TABLE
LUBRICANT
Transmission oil
PRODUCT
RECOMMENDED:
F.C., SAE 75W 90 or
GEAR SYNTH, SAE
75W - 90
High quality oil with performance equal to or better than A.P.I. GL-4 specifications can be used in alternative to the recommended oil.
Engine oil
RECOMMENDED:
GREEN HIT 2 or
CITY 2T
High quality oil with performance equal to or better than ISO L
ETEC++, A.P.I. TC++ specifications can be used in alternative to the recommended oil.
Fork oil
RECOMMENDED:
F.A. 5W or
F.A. 20W; alternatively
FORK 20W.
FORK 5W or
Whenever requiring an intermediate performance, between that offered by
F.A. 5W and from
F.A. 20W, the products can be mixed as shown
FORK 5W and from
FORK 20W, the prodbelow, or from
ucts can be mixed as shown below:
F.A. 5W 67% of volume +
F.A. 20W 33% of volume, or.
SAE 10W =
FORK 5W 67% of volume +
FORK 20W 33% of volume:
SAE 15W =
F.A. 5W 33% of volume, +
F.A. 20W 67% of volume,
or.
FORK 5W 33% of volume +
FORK 20W 67% of volume.
Bearings and other lubrication points
Battery poles
Brakes liquid
RECOMMENDED:
AUTOGREASE MP or
GREASE 30.
Alternatively to the recommended product use high quality grease for roller
bearings, temperature field capacity 150C230C, 150C230C drop
point, high anticorrosive protection, good water and oxidation resistance.
Neutral grease or Vaseline.
IMPORTANT Only use new brakes liquid. Never mix different brands or
types of oil without checking the compatibility of the bases.
Autofluid FR. DOT 4 (DOT 5 comThe braking system is loaded with
BREAKE 5.1, DOT 4 (DOT 5 compatibility).
patibility) or
Engine coolant
IMPORTANT Only use nitrite free antifreeze and anticorrosive, which ensures protection at least to 35 C..
RECOMMENDED:
ECOBLU 40 C or
COOL.
1-7
UPDATES
1.3.
1.3.1.
REGULAR MAINTENANCE
REGULAR MAINTENANCE SHEET
Components
Rear shock absorber
Battery Electrolyte level
Spark plug
Carburettor Idle
Transmission cables and controls
Vee-belt
Steering stem bearings and steering play
Wheels bearings
Brake discs
Piston rings
Air filter
Fuel filter
Throttle functioning
General vehicle functioning
Lights system
Brake light switch
Braking systems / brake discs
Cylinder cooling system
Brakes fluid (level check)
Brakes fluid
Coolant
Exhaust pipe / exhaust silencer
Mixer / throttle functioning
Mixer oil
Fork oil and front oil seal
Transmission oil
Mobile/fixed front pulley
Injector cleaning
Front variator rollers and guides
Wheels, tyres and inflation pressure
Nuts and bolts tightening
Battery terminals tightening
Mixer oil reserve indicator
Fuel tubing
Braking system tubing
Mixer oil tubing
Front and rear brake pads wear
Clutch wear
End of running
Every 5000 Km
Every 10000 Km
in period
(3100 mi) or
(6200 mi) or
[500 Km
12 months
24 months
(312 mi)]
1
1
1
1
3
4
1
1
1
3
1
1
1
1
1
Every 12000 Km (7440 mi): 1
1
3
1
3
1
1
1
1
1
1
1
1
1
Every 20000 Km (12400 mi): 2 (external cleaning)
1
Every two years: 3
Every 2000 Km (1240 mi): 1 / Every 2 years: 3
1
1
1
Every 2000 Km (1240 mi): 1
Every 12000 Km (7440 mi): 1
Every 12000 Km
3
1
(7440 mi) or 2 years: 3
Every 12000 Km (7440 mi): 1
Every 16000 Km (9920 mi): 2
Every 12000 Km (7440 mi): 3
1
1
Every month: 1
1
1
1
1
1
Every 5000 Km (3100 mi): 2 / Every two years: 3
Every 5000 Km (3100 mi): 1 / Every four years: 3
1
1
Every two years: 3
1
Every 2000 Km (1250 mi): 1
1
-
1 = check and clean, adjust, lubricate or replace if necessary; 2 = clean; = 3 replace; = 4 adjust.
Carry out maintenance operations more frequently if the vehicle is used in rainy, dusty areas, over bumpy terrain or if
driven sportily.
) = WORK WHICH CAN BE CARRIED OUT BY THE USER
(
(**) = Check every fifteen days or at the indicated intervals.
1-8
UPDATES
1.3.2.
FIXING ELEMENTS
CAUTION
The fixing elements reported in the table must be tightened to the prescribed pair using a dynamometric key and LOCTITE where specified.
Notes:
L243= fix it with Loctite 243
Lub= lubricate
Component
Quantity
Measure
Pair Nm
M6x30
M10x205
50
M10x230
42
Screw M8x70
25
M8x25
25
M10x35
50
M10x55
50
M6x35
10
Fixing filter housing on engine clamp
M6x60
10
Fixing hose collar on throttle body
Frame
Fixing rear handle
Engine connecting element
Engine pivot pin
Connecting rod pivot pin
Central stand
Central stand front attachment
Central stand rear attachment
Rear shock absorber
Fixing shock absorber lower screw
Fixing shock absorber top screw
Motor
Fixing CVT cover
Filter housing
2
Fixing filter housing clamp to engine
Fixing intake union support to engine
M6x40
M6x30
M6x35
Flange exhaust pipe on cylinder
Nut M6
10
Fix plate on engine
M8x85
25
Water cooler-head tube clamp on head
Nut 16-24x8
Water cooler-pump clamp on pump
17-25
Front wheel pin
M12x1.25
50
Wheel pin clump
M6
12
10
10
Exhaust system
Water cooler
Front wheel
Rear wheel
Rear wheel hub nut
M16
130
Fixing rear wheel on hub
M10x55
50
Front brake
Fixing left brake pump
M6
10
Fixing front brake caliper
M8x35
27
Rear brake pipe
M6x35
10
Fixing left brake pump
M6
10
Fixing rear brake caliper
M8x30
27
Rear brake
P.S.: All the pairs identified represent the nominal value. The range allowed is+ or 5%.
1-9
UPDATES
Component
Quantity
Measure
Pair Nm
Handlebar and Controls

Handlebar locking screw
M8x40
25
Handlebar clump screw
M10x55
50
Fixing steering nut
M36x1
10
Steering fixing return nut
Self locking
110
Fixing I.E. control unit
M5x16
Fixing pressure sensor support
M6x16
M6x16
Nut M4 selflocking
M6x16
M6x12
Fixing rear mudguard
M5
Fixing exhaust pipe protection
M6x16
Fixing fairing glass
M5x35
1.5
Fixing fuel pump pin
M5x35
Electrical system
Fixing ground cables

Fuel tank
Fixing fuel level sensor
Saddle
Fixing rider saddle screws on saddle
Fixing saddle pillar screws on saddle
Front body
Locks
Fixing commutator key
M6x17
shearing
M6x16
Fixing saddle lock
M6x40
Fixing commutator key
P.S.: All the pairs identified represent the nominal value. The range allowed is+ or 5%.
1 - 10
12
12
4
1.3.3.
UPDATES
MIXER OIL PUMP ADJUSTMENT

Remove the guard protection, see (REMOVING THE
CRANKCASE COVER)
Remove the small rubber plug (1).
Loosen the locking nut (2) and by manoeuvring on the

adjuster (3) align the two marks on the mixer oil pump
1 - 11
UPDATES
1.3.4.
IDLE ADJUSTMENT
The idle adjustment cannot be carried out
1 - 12
1.4.
1.4.1.
UPDATES
FUEL SUPPLY SYSTEM

PUMPING OUT THE FUEL TANK
Remove the rear fairing, see (REMOVING THE REAR
FAIRING).
Using a pipe wrench, pinch the tank-pump pipe (1).
Remove the clamp (2).
Remove the pipe (1) from the pump.
Position the pipe (1) in an adequate holding capacity
container.
Remove the pipe wrench and empty the fuel tank into
the container.
1 - 13
UPDATES
1.4.2.
REMOVING THE FUEL TANK

Remove the helmet carrying case, see (REMOVING
THE HELMET COMPARTMENT).
CAUTION
Empty the fuel tank prior to removing it.
Empty the fuel from the tank, see (DRAINING THE

FUEL TANK).
Disengage the fuel sensor connector (1).
Disengage the fuel supply pump connector (2).
Disengage the two quick couplings (3-4) on the fuel

rail.
Remove the fuel tank (5).
1 - 14
1.4.3.
UPDATES
REMOVING THE EXHAUST SYSTEM
Unscrew and remove the two nuts (1) from the exhaust
manifold.
Unscrew and remove the two screws (2).

Remove the exhaust system (3).
IMPORTANT When reassembling, replace the gasket between exhaust manifold and exhaust system, with a new
one.
CAUTION
Plug the exhaust manifold to ensure that impurities or foreign bodies cannot enter.
1 - 15
UPDATES
1.4.4.
REMOVING THE ENGINE

Remove the guard protection, see (REMOVING THE
CRANKCASE COVER).
Remove the fuel tank, see (REMOVING THE FUEL
TANK).
Remove the air filter pipe (1)
Unscrew and remove the two screws (2), and recover
the fairleads (3).

Remove the rear brake caliper (5).
Remove the small rubber plug (6).
Open the tab (7) and pull the cable out (8).
1 - 16
Loosen the throttle cable adjuster screw (9).

Remove the throttle cable (10) from the throttle body.
Disengage the sparkplug cap (11).
Empty the cooling system, see (DRAINING THE

COOLING SYSTEM).
Remove the clamp and disengage the return hose from
the thermostat valve
UPDATES
1 - 17
UPDATES
Fold the pipes over (13-14) and tighten them with some
clamps.
Disengage the connectors in the following order:

Alternator connector (15);
Fuel Rail connector (16);
Water temperature thermistore connector (17);
1 - 18
-
Air injector connector (18);
Throttle sensor connector (19).
Relay starter connector (20).
UPDATES
1 - 19
UPDATES
Loosen the screw and remove the two ground cables

(22-23).
Remove the clamp
Using a belt and a horse, lift the rear part of the vehicle.
Remove the rear shock absorber lower screw.
Working from the right hand side, loosen and remove
the nut (25); remove the pin from the opposite side.
Remove the engine.
1 - 20
1.4.5.
UPDATES
INSTALLING THE ENGINE
Shift the frame little by little until the fixing holes are
perfectly aligned.
Insert the pin (1).
Lock the nut (2).
Insert the pipe (3) into the coolant pump.

Block the pipe (3) with the clamp.
Insert the pin (4) into the lower part of the shock absorber and lock the nut (5).
1 - 21
UPDATES
Insert the pipe (6) into the thermostat valve.
Connect the sparkplug cap (7) correctly.
Connect the following electrical connectors in this order:

Alternator connector (8);
Fuel Rail connector (9);
1 - 22
-
Water temperature thermistore connector (10);
Air switch connector (11);
Throttle sensor connector (12);
Relay starter connector (13).
UPDATES
1 - 23
UPDATES
Place the two ground cables (14-15) and lock the

screw.
Put in place the mixer oil pump cable (16) again in its
proper lodging and close the tab (17).
Put in place the throttle cable (18) again in its proper

lodging.
Synchronize the oil pump cable with the throttle cable
and adjust the play.
Reassemble the small rubber plug (19).
1 - 24
Reassemble the air filter pipe (20).

Put the two fairleads (21) in place again and lock the
two screws (22).
Position the brake caliper and lock the two screws (23).
Insert the oil pipe in the fairlead (24) of the protection

guard
Assemble the protection guard
Assemble the fuel tank
Refill the cooling system
UPDATES
IMPORTANT Perform a general inspection of all the components which were subject to operations and check specifically:
-
the correct fixing of electrical cables with the proper

clamps;
CAUTION
No twisting or flattening must be present.
the correct coupling of the electrical connectors;

the correct insertion of pipelines, couplings and the related fixing with fitting clamps;
the throttle cable must slide freely without stretching at
the handlebar rotation.
1 - 25
UPDATES
1.5.
CHASSIS
1.5.1.
REMOVING THE REAR MUDGUARD

Working from the right hand side, unscrew and remove
the screw (1).
Working from the top side, unscrew and remove the
screw (2).
Working from the left hand side, unscrew and remove

the screw (3).
Remove the rear mudguard (4).
1 - 26
1.5.2.
UPDATES
REMOVING THE CRANKCASE COVER
Unscrew and remove the three screws (1).

Remove the rear brake oil pipe (3) from the fairlead (4).
Remove the crankcase cooling pipe (5).

Remove the crankcase cover (6).
1 - 27
UPDATES
1.5.3.
REMOVING THE CENTRAL STAND

the screw (1) and collect the washer.
Working from the left hand side, unscrew and remove

the screw (2) and collect the washer.
Unscrew and remove the nut (3) and remove the pin
from the opposite side (4).
Remove the central stand assembly (5).
1 - 28
1.5.4.
UPDATES
REAR WHEEL DIAGRAM
Legend:
1. Tyre
2. Rear wheel
3. Brake disc
4. Tubeless valve
5. Pads
6. Rear brake caliper
7. Air bleed valve
8. Rear brake pipe
9. Rear wheel nut
10. Rear wheel plug
11. Ring
12. Pin + caliper spring
13. Rear hub
14. Split pin
15. Cap
1 - 29
UPDATES
1.5.5.
REMOVING THE REAR WHEEL
Remove the exhaust, see (REMOVING THE EXHAUST SYSTEM).

Remove the plug (1).

Remove the rear wheel (3).
1 - 30
1.5.6.
UPDATES
REMOVING THE REAR WHEEL HUB

Remove the rear wheel, see (REMOVING THE REAR
WHEEL).
Remove the split pin (1) and collect the plug (2).
IMPORTANT The split pin must be replaced every time that

it is disassembled.
Unscrew and remove the nut (3) and collect the washer.
Remove the rear wheel hub (4).
1 - 31
UPDATES
1.5.7.
REMOVING THE REAR BRAKE DISC

Remove the rear wheel hub, see (REMOVING THE
REAR WHEEL HUB).
Remove the rear brake disc (2).
1 - 32
1.5.8.
UPDATES
REMOVING THE SHOCK ABSORBER

Position the vehicle on the central stand.
CAUTION
Place a sufficient spacer under the rear wheel,
to prevent lowering and the consequent pushing of the air filter housing on the inspection
cover.
Remove the rear fairing, see (REMOVING THE REAR

FAIRING).
CAUTION
Prop up the rear part of the chassis to prevent it
lowering during the removal of the shock absorber.
Unscrew and remove the upper screw (1) and collect

the washer.
Unscrew and remove the nut (2) and remove the screw
(3).
Remove the rear shock absorber (4).
1 - 33
UPDATES
1.5.9.
REMOVING CONNECTION ELEMENTS
Remove the engine, see (REMOVING THE ENGINE).

Working from right hand side, loosen and remove the
nut (1).
Working from left hand side, pull the pin (2) out.
Remove the connection elements (3) and recover (4)
the spacer.
1 - 34
1.6.
1.6.1.
UPDATES
ELECTRICAL SYSTEM
COMPONENTS INSPECTION
1
Alternator:
Three-phase alternator
1 ohm winding resistance
50 AC outlet voltage (to be measured when the alternator is
disengaged from electrical system and the engine is running
at 3000 rpm)
2
Engine revolutions sensor:
inductive sensor
1 - 35
UPDATES
3
Starter motor
Steady-state power absorbed at 20 A
4
Fuel pump:
0.35 A absorbing
5
Taillights:
rear position light 12 V - 5 W
rear stop light 12 V - 10 W
6
Ignition coil:
0.7 ohm primary resistance
1 - 36
UPDATES
7
Fuel level sensor:
resistance between trailings 1 and 3:
5 ohm with a full tank
38 ohm with a half full tank
100 ohm with an empty tank
8
Fuses:
Fuse 7.5 A (A) - From key commutator to:
turn indicators system;
horn;
fuel level system;
water temperature;
oil level.
Fuse 15 A (B) - From battery to:
injection system;
battery recharge;
starter;
engine stop lights.
9
Recharging voltage:
13.50.3 V voltage to note at the battery poles (with the engine at 3000 rpm)
10
Headlight:
low beam
low/high beam
12 V - 15 W
12 V - 35/35 W
1 - 37
UPDATES
11
Throttle body
FUEL INJECTOR:
Winding resistance 1.7 ohm
STRENGHTENING THROTTLE (TPS):
resistance between trailings 1 and 4
Throttle OFF
Throttle ON
Tolerance +-10% on the values noted
12
Air injector:
winding resistance 1.3 ohm
13
Coolant temperature sensor
NTC sensor
Resistance 2.7 kohm at 20 C
1 - 38
1.1 kohm
1.1 kohm
1.9 kohm
1.9 kohm
1.1 kohm
1.6.2.
UPDATES
ELECTRICAL DIAGRAM
1 - 39
UPDATES
Legend
1) Oil level switch
2) Injection check indicator
3) Water temperature instrument
4) Turn indicators indicator
5) Oil level indicator
6) Dashboard lighting lamps
7) Fuel level instrument
8) Lights on indicator
9) Fuel reserve indicator
10) Dashboard
11) Fuel level sensor
12) Horn
13) Horn button
14) Key commutator
15) Flasher unit
16) Turn indicators deflector
17) Pressure sensor
18) Start pushbutton
19) Control diode
20) Rear left turn indicator
21) Tail light
22) Side light lamp
23) Stop light lamp
24) Rear right turn indicator
25) Rear stop switch
26) Front stop switch
27) Alternator
28) Tension regulator
29) Starter relay
30) Starter motor
31) Fuses
32) Battery
33) HT coil
34) Spark plug
35) Fuel pump
36) Air injector
37) Fuel injector
38) Multiple connectors
39) Injector relay
40) Head temperature sensor
41) Pick up
42) Throttle sensor
43) Serial connection (Diag)
44) ECU control unit
45) Front right turn indicator
46) Head light
47) Low beam lamps
48) Front left turn indicator
49) Oil pump
1 - 40
1.7.
1.7.1.
UPDATES
GENERAL INFORMATION
REFERENCE MANUALS
ENGINE WORKSHOP MANUALS

8140731
8140732
8140733
8140734
8140735
8140736
SPARE PARTS CATALOGUES
553Y
SPECIAL TOOLS MANUALS
001H
USE AND MAINTENANCE BOOKLETS
8202336
8202381
8202382
CHASSIS WORKSHOP MANUALS
8140123
8140124
1 - 41
UPDATES
1.8.
1.8.1.
SPECIFICATIONS
SPECIFICATIONS
DIMENSIONS
Max length (with rear mudguard extension)
Max width
Max. height (to the windshield)
Height to the saddle
Wheelbase
Minimum clear height from the ground
Running conditions weight
ENGINE
Type
Model
Number of cylinders
Total capacity
Bore/stroke
Compression ratio
Starter
Engine idle rpm
Clutch
Gear
Cooling
CAPACITY
Fuel (reserve included)
Fuel reserve
Transmission oil
Mixer oil (reserve included)
Mixer oil reserve
Coolant
Seats
Max vehicle load (pilot+luggage)
Max vehicle load (pilot+ passenger + luggage)
TRANSMISSION
Variator
Primary
Ratios
minimum for continuous variable transmission
maximum for continuous variable transmission
Secondary
CARBURETTOR
MODEL
standard
Diffusor
SUPPLY
Fuel
CHASSIS
Type
SHOCK ABSORBERS
Front
Travel
Rear
Travel
BRAKES
Front
Rear
WHEELS
Type
Front
Rear
1 - 42
1775 mm
720 mm
1200 mm
820 mm
1265 mm
160 mm
106 Kg
Two-stroke
C364M
Horizontal single cylinder
3
49.38 cm
40 mm / 39.3 mm
12.1 0.5 : 1
electric + kick starter
1800 100 rpm
Dry automatic centrifugal
Automatic continuous variator
Liquid
8l
2l
3
130 cm
1.6 l
0,5 l
1.2 l (50% antifreeze with ethylene glycol + 50% water)
1
(2 in countries which allow passengers to be carried)
105 Kg
180 Kg
Automatic continuous
V-belt
3.07
0.78
gears
DellOrto PHBN17.5
17,5 mm
Premium unleaded petrol DIN 51607, with minimum octane number 95 (N.O.R.M.) and 85 (N.0.M.M.)
Split single beam
Telescopic fork
90 mm
Hydraulic single shock
72 mm
Alloy
3.50 x 13"
3.50 x 13"
UPDATES
TYRES
Type
Front
Rear
STANDARD INFLATION PRESSURE
Front
Rear
INFLATION PRESSURE WITH PASSENGER
Front
Rear
IGNITION UNIT
Type
Ignition advance
SPARK PLUG
Standard
Spark plug electrodes distance
ELECTRICAL SYSTEM
Battery
Fuses
Alternator (permanent magnet)
BULBS
Low-beam
Low-beam / High-beam
Turn indicators
Rear side light
Rear stop light
Dashboard lighting
INDICATOR LIGHTS
Low-beam
High-beam
Turn indicators
Mixer oil reserve
Fuel reserve
tubeless
130/60 - 13" - 53J
130/60 - 13" - 53J
180 KPa (1.8 bar)
200 KPa (2.0 bar)
180 KPa (1.8 bar)
220 KPa (2.2 bar)
C.D.I.
20 3 before the T.D.C.
CHAMPION RN1C
0.6 0.7 mm
With maintenance 12 V - 4 Ah
7.5 A - 15 A
12 V - 70 W
12 V - 15 W
12 V - 35/35 W
12 V - 10 W
12 V - 5 W
12 V - 10 W
12 V 1.2 W
12 V 1.2 W
12 V 1.2 W
12 V - 2 W
12 V - 2 W
12 V 1.2 W
1 - 43
UPDATES
1.9.
1.9.1.
REGULAR MAINTENANCE
REGULAR MAINTENANCE SHEET
Components
Rear shock absorber
Battery Electrolyte level
Spark plug
Carburettor Idle
Transmission cables and controls
Vee-belt
Steering stem bearings and steering play
Wheels bearings
Brake discs
Piston rings
Air filter
Fuel filter
Throttle functioning
General vehicle functioning
Lights system
Brake light switch
Braking systems / brake discs
Cylinder cooling system
Brakes fluid (level check)
Brakes fluid
Coolant
Exhaust pipe / exhaust silencer
Mixer / throttle functioning
Mixer oil
Fork oil and front oil seal
Transmission oil
Mobile/fixed front pulley
Front variator rollers and guides
Nuts and bolts tightening
Battery terminals tightening
Mixer oil reserve indicator
Fuel tubing
Braking system tubing
Mixer oil tubing
Front and rear brake pads wear
Clutch wear
End of running
Every 5000 Km
Every 10000 Km
in period
(3100 mi) or
(6200 mi) or
[500 Km
12 months
24 months
(312 mi)]
1
1
1
1
3
4
1
1
1
3
1
1
1
1
1
Every 12000 Km (7440 mi): 1
1
3
1
3
1
1
1
1
1
1
1
1
1
Every 20000 Km (12400 mi): 2 (external cleaning)
1
Every two years: 3
Every 2000 Km (1240 mi): 1 / Every 2 years: 3
1
1
1
Every 500 Km (312 mi): 1
Every 12000 Km (7440 mi): 1
Every 12000 Km
3
1
(7440 mi) or 2 years: 3
Every 12000 Km (7440 mi): 1
Every 12000 Km (7440 mi): 3
1
1
Every month: 1
1
1
1
1
1
Every 5000 Km (3100 mi): 2 / Every two years: 3
Every 5000 Km (3100 mi): 1 / Every four years: 3
1
1
Every two years: 3
1
Every 2000 Km (1250 mi): 1
1
-
1 = check and clean, adjust, lubricate or replace if necessary; 2 = clean; = 3 replace; = 4 adjust.
Carry out maintenance operations more frequently if the vehicle is used in rainy, dusty areas, over bumpy terrain or if
driven sportily.
) = WORK WHICH CAN BE CARRIED OUT BY THE USER
(
(**) = Check every fifteen days or at the indicated intervals.
1 - 44
UPDATES
1.10. SUPPLY SYSTEM

1.10.1.
REMOVING THE SPARK PLUG
Remove the glove compartment, see (REMOVING

THE GLOVE COMPARTMENT).
Remove the spark plug cap. Rim
Unscrew and remove the spark plug.
1 - 45
UPDATES
1.10.2.
REMOVING THE CARBURETTOR
Unscrew and remove the two screws
Unscrew and remove the screw
Loosen the clamp on the carburettor.
Remove the filter housing.
1 - 46
Disconnect the automatic starter connector.
Pinch the two heater pipes.

Remove the two clamps and disconnect the pipes.
Pinch the fuel pipe.

Remove the clamp and disconnect the fuel pipe.
Pinch the oil pipe.

Remove the clamp and disconnect the oil pipe.
UPDATES
1 - 47
UPDATES
Remove the clamp and disconnect the vacuum pipe.
Loosen the clamp and remove the carburettor from the

intake manifold.
Unscrew and remove the screw and remove the throttle cable with the exhaust valve.
1 - 48
1.10.3.
UPDATES
REMOVING THE VACUUM FUEL TAP
Lift the saddle, see (LIFTING THE SADDLE).

Remove the rubber protection.
Unscrew and remove the two front screws.
Unscrew and remove the two central screws.
Unscrew and remove the four screws and remove the

rear handle.
Unscrew and remove the two rear screws.
1 - 49
UPDATES
Working from both sides, unscrew and remove the side

screw.
Remove the rear fairing.
Disconnect the connector.
Empty the fuel tank, see (DRAINING THE FUEL

TANK).
Remove the clamps and unhook the pipes.
1 - 50
SR 50 TE ( Engine C364M)
UPDATES
Loosen the clamp and remove the vacuum fuel tap.
1 - 51
UPDATES
1.10.4.
REMOVING THE ENGINE
Remove the air filter pipe.

Remove the brake caliper, see (REMOVING THE
BRAKE CALIPER).
Unscrew and remove the fifteen screws and remove
the variator cover.
Unhook the oil pump pipe.
Pinch the delivery oil pipe.

Remove the clamp and remove the pipe.
Remove the carburettor, see (REMOVING THE CARBURETTOR).

Remove the spark plug cap.
Disconnect the temperature sensor connector.
1 - 52
Remove the two rear panels, see (REMOVING THE

REAR PANELS).
Remove the exhaust, see (REMOVING THE EXHAUST).
Disconnect the generator connector.
Unscrew and remove the four screws.
Remove the clamp and remove the cover.
Unscrew and remove the two upper screws of the lower lockup.
UPDATES
1 - 53
UPDATES
Unscrew and remove the lower screw of the lower lockup.

Lower the lower protection.
Unscrew and remove the screw and remove the starter

motor ground wire.
Remove the clamp.
Disconnect the connector.
1 - 54
Unscrew and remove the drain screw of the cooling

system and drain it.
Loosen the clamp and remove the thermostatic valve

pipe.
Using a belt and a suitable tool, lift the rear part of the
vehicle.
Remove the rear shock absorber lower screw, see
(REMOVING THE REAR SHOCK ABSORBER).
the nut.
UPDATES
Remove the pin from the opposite side.

Remove the engine.
1 - 55
UPDATES
1.11. ELECTRICAL SYSTEM

1.11.1.
COMPONENTS INSPECTION
1
Alternator:
Two-phase alternator
0.51 ohm winding resistance
30-35 AC outlet voltage (to be measured when the alternator is disengaged from electrical system and the engine is
motoring over)
2
Engine revolutions sensor:
inductive sensor
1 - 56
UPDATES
3
Starter motor
Steady-state power absorbed at 20 A.
4
Taillights:
rear position light
rear stop light
12 V 5 W
12 V 10 W
5
Fuel level sensor:
resistance (between trailings 1 and 2)
5 ohm
with a full tank
100 ohm with an empty tank
38 ohm
with a half full tank
6
Fuses:
DISPOSIZIONE FUSIBILI
Fuse 7.5 A (A) - From key commutator to:
stop light circuit;
mixer oil reserve sensor circuit;
fuel level sensor circuit;
coolant thermistor circuit;
CDI circuit;
turn indicators circuit;
horn.
Fuse 10 A (B) - From battery to:
tension regulator;
ignition/steering lock switch;
thermal switch;
PTC.
1 - 57
UPDATES
7
Headlight:
low beam
12 V 15 W
low/high beam 12 V 35/35 W
8
Engine temperature sensor:
NTC sensor
Resistance 560 ohm (temperature 25C)
Resistance 40 ohm (temperature 100C)
1 - 58
1.11.2.
UPDATES
ELECTRICAL DIAGRAM
1 - 59
UPDATES
1) Alternator
2) CDI
3) Sparkplug
4) HT coil
5) Tension regulator
6) Battery
7) Starter motor
8) Starter relay
9) Front stop switch
10) Rear stop switch
11) Mixer oil reserve switch
12) Coolant thermistor
13) Fuel level sensor
14) Rear right turn indicator
15) Tail light
16) Rear left turn indicator
17) Light switch
18) Horn button
19) Ignition/steering lock switch
20) Control diode
21) Start pushbutton
22) Flasher unit
23) Dashboard
24) Turn indicators indicator
25) Mixer oil reserve indicator
26) Dashboard lighting lamps
27) Fuel level instrument
28) Fuel reserve indicator
29) Low beam indicator
30) Coolant temperature instrument
31) Front right turn indicator
32) Front left turn indicator
33) Head light
34) Low beam lamps
35) Horn
36) Pick up
37) Fuses
38) Multiple connectors
39) Rear side light lamp
40) Stop light lamp
41) Turn indicators deflector
42) Thermal switch
43) 44) Automatic starter
45) 46) PTC
1 - 60

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UPDATES

ENGINE WORKSHOP MANUALS

POSITION OF THE SERIAL NUMBERS

Bearings and other lubrication points

Fixing filter housing on engine clamp

Fixing hose collar on throttle body

Fixing filter housing clamp to engine

Fixing intake union support to engine

Flange exhaust pipe on cylinder

Fix plate on engine

Water cooler-head tube clamp on head

Water cooler-pump clamp on pump

Front wheel pin

Wheel pin clump

Fixing rear wheel on hub

Fixing front brake caliper

Rear brake pipe

Fixing left brake pump

Fixing rear brake caliper

Handlebar and Controls

Handlebar clump screw

Fixing steering nut

Steering fixing return nut

Fixing I.E. control unit

Fixing pressure sensor support

Fixing rear mudguard

Fixing exhaust pipe protection

Fixing fairing glass

Fixing fuel pump pin

Fixing ground cables

Fixing commutator key

Fixing saddle lock

Fixing commutator key

MIXER OIL PUMP ADJUSTMENT

Loosen the locking nut (2) and by manoeuvring on the

The idle adjustment cannot be carried out

FUEL SUPPLY SYSTEM

REMOVING THE FUEL TANK

Empty the fuel from the tank, see (DRAINING THE

Disengage the fuel supply pump connector (2).

Disengage the two quick couplings (3-4) on the fuel

Remove the fuel tank (5).

REMOVING THE EXHAUST SYSTEM

Unscrew and remove the two screws (2).

REMOVING THE ENGINE

Unscrew and remove the two screws (4).

Remove the small rubber plug (6).

Loosen the throttle cable adjuster screw (9).

Disengage the sparkplug cap (11).

Empty the cooling system, see (DRAINING THE

Remove the clamp (12).

Disengage the connectors in the following order:

Fuel Rail connector (16);

Water temperature thermistore connector (17);

Air injector connector (18);

Throttle sensor connector (19).

Relay starter connector (20).

Remove the clamp (21).

Loosen the screw and remove the two ground cables

Remove the clamp

Remove the engine.

INSTALLING THE ENGINE

Lock the nut (2).

Insert the pipe (3) into the coolant pump.